Powertrain Strategies for the 21st
Century: Next Generation
Electric Vehicle Strategies
Li-ion Batteries for
Electrified Mobility
Ann Arbor, MI | 20.07.2016
Jacob Bemrich, PE
Systems Engineering Manager
Robert Bosch Battery Systems LLC
Robert Bosch Battery Systems LLC | BBSN/ENA1 | 7/20/2016
© 2016 Robert Bosch LLC and affiliates. All rights reserved.2
Bosch Powertrain Electrification – future mobilityWorldwide Footprint
Stuttgart (Region)
Headquarter EM, LE, BATResearch & Development
EM: E-Motor
PE: Power Electronics
BAT: Battery Pack
CELL: Battery Cell
Detroit (Region)
Farmington Hills,
local office
PE Dev & Plant
Reutlingen
EM Plant
Hildesheim
Tokyo (Region)
Yokohama, local office
Shanghai UAES
Development & Plant
PE Dev. & Plant
Budapest &Hatvan
BAT Plant
Suzhou
BAT Plant
Bamberg
BAT Development
Orion
BAT Plant
Springboro
Cell Development
Stuttgart
Cell Dev. & Plant
Kyoto & Ritto
PE SW/HW Develop.
Coimbatore, Bangalore
Cell Development
Hayward
~ 1800 employees working on power train electrification within Bosch group
R&D and Production
Robert Bosch Battery Systems LLC | BBSN/ENA1 | 7/20/2016
© 2016 Robert Bosch LLC and affiliates. All rights reserved.3
Global Locations – North America
Springboro, Ohio Production plant, (50,000+
vehicle packs built since 2006, Li-Ion SOP
Nov 2012)
Technical and Product Services in place for
Aftermarket to support complete Product Life Cycle
Approx. 150 employees
Orion, Michigan Engineering facility (several
OEM projects since 2005)
Experienced xEV battery pack mechanical, HW-, SW- and
systems-engineering
On-site development labs, test labs, and validation
facilities for Li-ion
Approx. 100 employees
Mission:
Produce and Deliver ‘Zero Defect’
Battery Packs ‘On-time’ for Production
and Service Customers.
170,000 ft2 (16,000 m2)
Expandable to 213,000 ft2
R&D and Production
Robert Bosch Battery Systems LLC | BBSN/ENA1 | 7/20/2016
© 2016 Robert Bosch LLC and affiliates. All rights reserved.4
Influence variables on eMobility
• Applications
• Market volume
• Customer expectations
• Requirements
Technology
Web 3.0EV-train
KPIs
Infrastructure
Megatrends
electrified, automated, connected
Business models
Legislation
User experience UX
Robert Bosch Battery Systems LLC | BBSN/ENA1 | 7/20/2016
© 2016 Robert Bosch LLC and affiliates. All rights reserved.5
Content
Market requirements for batteries 2020ff – the Bosch view
Applications
Market volume
Customer expectations
Battery requirements
KPIs
Technologies to reach the targets
Battery cell technologies – until 2020 LIT
From 2020: PLIT
Summary and prospect
Bosch 48V Mild HEV
Robert Bosch Battery Systems LLC | BBSN/ENA1 | 7/20/2016
© 2016 Robert Bosch LLC and affiliates. All rights reserved.6
Applications
HEV PHEV EV BRS
Generation 1 (series)
Generation 2 (in development)
Electrical range
Electrical power
Challenges • High power
• Low cost
Technology Li-ion
(available)
HEV PHEV EV BRS
Generation 1 (series)
Generation 2 (in development)
Electrical range
Electrical power
Challenges • High power
• Low cost
• High performance
• Cycle life
• Cost down
Technology Li-ion
(available)
Li-ion
(improved)
HEV PHEV EV BRS
Generation 1 (series)
Generation 2 (in development)
Electrical range
Electrical power
Challenges • High power
• Low cost
• High performance
• Cycle life
• Cost down
• High energy
density
• Cost down
Technology Li-ion
(available)
Li-ion
(improved)
Li-ion
(improved)
Post Li-ion
Applications
HEV PHEV EV BRS
Generation 1 (series)
Generation 2 (in development)
Electrical range
Electrical power
Challenges • High power
• Low cost
• High performance
• Cycle life
• Cost down
• High energy
density
• Cost down
• High power
• Low cost
Technology Li-ion
(available)
Li-ion
(improved)
Li-ion
(improved)
Post Li-ion
Li-ion
(available)
HEV PHEV EV BRS
Generation 1 (series)
HEV PHEV EV BRS
Generation 1 (series)
Generation 2 (in development)
BBSD/ENA | 7/20/2016
© 2016 Robert Bosch LLC and affiliates. All rights reserved.7
Market volume
1.5
6 5.30.1
4.58.3
0.2
2.5
8
0
5
10
15
20
25
2014 2020 2025
Un
its [m
io. ve
hic
les]
Vehicle sales PC incl. LCV<6t: Estimation Bosch
HEV Hybrid Electric Vehicle PHEV Plug-in Hybrid Electric Vehicle EV Electric Vehicle
Total vehicle market: 12511285
21,6
13
1,8
PHEV and EV with strong growth
HEV volume declining
Robert Bosch Battery Systems LLC | BBSN/ENA1 | 7/20/2016
© 2016 Robert Bosch LLC and affiliates. All rights reserved.8
Consequences on production capacity
3 12 111
68166
4 150
600
400
100
200
300
400
500
600
700
800
900
2014 2020 2025
Pro
du
ctio
n c
ap
acity [G
Wh
/ye
ar]
HEV Hybrid Electric Vehicle PHEV Plug-in Hybrid Electric Vehicle EV Electric Vehicle
Required battery production capacity
777
230
8
Li-ion Consumer 2014
Robert Bosch Battery Systems LLC | BBSN/ENA1 | 7/20/2016
© 2016 Robert Bosch LLC and affiliates. All rights reserved.9
Customer expectations towards an EV
Driving range ≥ 350 km
Good performance
Fast charging
No battery exchange
during vehicle life
Reasonable safety
Affordable
Customer expectations Battery requirements
≥ 50kWh
200Wh/kg…400Wh/kg
150kW…250kW
P/E ratio 3…5
250km
with 15min charge time
80% capacity &
performance @ 300Tkm,
> 10years
Safety level equal or higher
than in vehicle with ICE
Market price target battery:
6,600USD
Robert Bosch Battery Systems LLC | BBSN/ENA1 | 7/20/2016
© 2016 Robert Bosch LLC and affiliates. All rights reserved.10
KPIs: status 2015, market targets 2020 - 2025
Energy Density
Cost
Lifetime
Quality
Safety
Energy Density
Cost
Performance
Robert Bosch Battery Systems LLC | BBSN/ENA1 | 7/20/2016
© 2016 Robert Bosch LLC and affiliates. All rights reserved.11
KPIs: status 2015, market targets 2020 - 2025
Cost
0
100
200
300
400
500
2015 2020 2025
Cell Pack
Co
st
[EU
R/k
Wh
]
~ F
acto
r1
/4
~ F
acto
r1
/3
0
100
200
300
400
500
2015 2020 2025
Cell Pack
En
erg
y d
en
sit
y [
Wh
/kg
]
Energy Density
~ x
2~ F
acto
r3
EV
Robert Bosch Battery Systems LLC | BBSN/ENA1 | 7/20/2016
© 2016 Robert Bosch LLC and affiliates. All rights reserved.12
KPIs: status 2015, market targets 2020 - 2025
Cost
0
100
200
300
400
500
2015 2020 2025
Cell Pack
Co
st
[EU
R/k
Wh
]
~ F
acto
r1
/4
~ F
acto
r1
/3
EV
Robert Bosch Battery Systems LLC | BBSN/ENA1 | 7/20/2016
© 2016 Robert Bosch LLC and affiliates. All rights reserved.13
Content
Market requirements for batteries 2020ff – the Bosch view
Applications
Market volume
Customer expectations
Battery requirements
KPIs
Technologies to reach the targets
Battery cell technologies – until 2020 LIT
From 2020: PLIT
Summary and prospect
Bosch 48V Mild HEV
Robert Bosch Battery Systems LLC | BBSN/ENA1 | 7/20/2016
© 2016 Robert Bosch LLC and affiliates. All rights reserved.14
Battery cell technologies
LIT: Li-ion Technology PLIT: Post Li-ion Technology
Conversion
cathode
>2025
Li-S
>2025
EV with solid state
electrolyte, SOP > 2020
Gravimetric energy density cell [Wh/kg]
Vo
lum
etr
ic e
ne
rgy
de
ns
ity
[W
h/l
]
1500
1000
500
800400 600200
LIT Maximum
EV 2020
~ 800Wh/l
PHEV 2020:
~400Wh/l
• Market until 2020 dominated by Li-ion Technology (LIT)
• Energy density in 2020 already close to the technical limit of LIT
• Post Li-ion Technologies (PLIT) with potential for higher gravimetric and volumetric energy densities in combination with improved safety
• EVs w/ SOP > 2020: PLIT with solid state electrolyte very promising
Robert Bosch Battery Systems LLC | BBSN/ENA1 | 7/20/2016
© 2016 Robert Bosch LLC and affiliates. All rights reserved.15
PLIT cell technologies
Terminology
Li-ion Technology (LIT)
Lithium in both electrodes
mainly intercalated
Structure of electrodes hardly
changed due to intercalation
Li-ions migrate free
via (liquid) electrolyte
Post Li-ion Technology (PLIT)
At least one electrode not intercalating lithium
Acronym PLIT often used as synonym for Li-Sulfur and Li-Air technologies
Cells with metallic Lithium anode are counted among PLIT
Anode Separator Electrolyte Cathode
Charging
Discharging
Li+
Li+
Graphite Lithium-metal-oxide
Li
Robert Bosch Battery Systems LLC | BBSN/ENA1 | 7/20/2016
© 2016 Robert Bosch LLC and affiliates. All rights reserved.16
PLIT cell technologies, examples
Solid State Cells
Anode Separator Cathode
Charging
Discharging
Li+
Li+
Metallic
lithium
Solid state electrolyte
with active material
Polymer
Active
material
Li-Sulfur Technology
Anode Separator Electrolyte Cathode
Charging
Discharging
Li+
Li+
Metallic
lithium
Mixture of sulfur and carbon
particles with binder
S8
BinderLi2S
C
Li-Air Technology
Anode Separator/Electrolyte Cathode
Charging
Discharging
Li+
Li+
Metallic
lithium
Mesoporous
carbon
Solid state
electrolyte
Li2O2
Charging
Discharging
O2
O2
Cells with conversion cathode
Anode Separator Electrolyte Cathode
Charging
Discharging
Li+
Li+
Metallic
lithium
Metal fluoride
FeF2
Robert Bosch Battery Systems LLC | BBSN/ENA1 | 7/20/2016
© 2016 Robert Bosch LLC and affiliates. All rights reserved.17
Solid state cells, status Bosch
Bosch acquired Californian battery technology company Seeo
Engineering prototype cells available
Seeo DryLyteTM Technology
Dry Solid
Anode Lithium Foil
Separator
CathodeDry Solid
Polymer
Composite
Dry Solid
Electrolyte
Technology very promising: Lifetime > 1000 cycles reached with LFP cathode,
operating temperature 80..100°C
Robert Bosch Battery Systems LLC | BBSN/ENA1 | 7/20/2016
© 2016 Robert Bosch LLC and affiliates. All rights reserved.18
Solid state cells, Safety
Safety test results (LFP cathode, Li metal anode)
Z-Axis
X-Axis
Y-Axis
Test Result
Crush No smoke or flames
Penetration test No smoke or flames
Short circuit test No smoke or flames
Thermal shock No smoke or flames
Over-discharge No smoke or flames
Overcharge No smoke or flames
Thermal stability Stable up to 180°C
Intrinsic safety of Seeo technology is a big advantage
Crush test
Robert Bosch Battery Systems LLC | BBSN/ENA1 | 7/20/2016
© 2016 Robert Bosch LLC and affiliates. All rights reserved.19
Summary and prospect
Li-ion technology will dominate the market until 2020
Li-ion technology technical feasible for EV and PHEV
Technical limit of automotive Li-ion
expected @ ~350..400Wh/kg
Post Li-ion with potential to further
increase energy density and to reduce cost
Solid state cells for EV expected
to be ready for series past 2020
PLIT with high chance
for game changer
Robert Bosch Battery Systems LLC | BBSN/ENA1 | 7/20/2016
© 2016 Robert Bosch LLC and affiliates. All rights reserved.20
Content
Market requirements for batteries 2020ff – the Bosch view
Applications
Market volume
Customer expectations
Battery requirements
KPIs
Technologies to reach the targets
Battery cell technologies – until 2020 LIT
From 2020: PLIT
Summary and prospect
Bosch 48V Mild HEV
Bosch 48V Mild HEV
Robert Bosch Battery Systems LLC | BBSN/ENA1 | 7/20/2016
© 2016 Robert Bosch LLC and affiliates. All rights reserved.21
Evolution of Electrification
AStart
Stop2
46
x 1000 / min
40
80
160
200km/h
120
0
Coasting
Inn
ov
ati
on
lin
e
AStart
Stop2
46
x 1000 / min
40
80 120
160
200km/h0 20
A
Start
Stop2
46
40
80-
sHEV
Start/StopCoasting
AdvancedStart/Stop
24
6
x 1000 / min040
80 120
160
200km/h0
AStart
Stop
Baseline:Start/Stop
x 1000 / min
200km/h0
Recuperation
Boost
e-drive
Coasting
AStart
Stop2
46
x 1000 / min
40
80
160
200km/h
-
0
PHEV
160
Recuperation
Boost
e-drive
Coasting-
AStart
Stop2
46
x 1000 / min
40
80
160
200km/h0
48V Systems
Recuperation
Coasting
Boost
e-drive entry
Further improvement of cost-benefit
ratio plus feeling of electric driving
CO2 potential
ICE Dominant HEV Dominant
sHEV: ‘Strong Hybrid Electric Vehicle’; electric motor operation independent of engine state; typically operating at VDC>120
BBSN/ENA1 | 7/20/2016
© 2016 Robert Bosch LLC and affiliates. All rights reserved.22
Powertrain Scenarios – 48VBRS 48V shows considerable market growth
0
2
4
6
8
10
12
2020
3.1
2014
0.0
Un
its [m
io. ve
hic
les]
2025
11.3
Vehicle sales PC incl. LCV<6t1)
1) Estimation Bosch
total market 125 mio.112 mio.85 mio.
BRS 48V
BRS 48V Boost Recuperation System
Bosch 48V HEV
Robert Bosch Battery Systems | BBSN/ENA1 | 7/20/2016
© 2016 Robert Bosch LLC and affiliates. All rights reserved.23
Increasing Total System Power Required to Achieve Operation
Inc
rea
sin
g P
ow
er
Ne
ed
s f
or
Ind
ivid
ual C
om
po
nen
ts
Limited Change wrt.
TodayBrake Actuation
Electrical Power
Increased
EPS Power
Increased in coord.
w/ Brakes
Time to Stop
Further EPS Power
Increase
Longer Duration
Duration after
system electrical
failure
Power-Net Redundancy – Autonomous Functions
Bosch 48V HEV
Robert Bosch Battery Systems LLC | BBSN/ENA1 | 7/20/2016
© 2016 Robert Bosch LLC and affiliates. All rights reserved.24
Summary
48V seen as a bridge to a higher voltage future
‒ Main focus is on easy to integrate belt-machines
‒ Other topologies considered, but with a later implementation (post 2021)
‒ Cost effective CO2 reduction the main driver
Power-net requirements may drive manufacturers towards 48V solutions
‒ Highly Automated Driving will require redundant and powerful actuation systems
pushing charging systems to their limit
New concepts may change the landscape
‒ SSC could be one path where a non-traditional strategy that delivers real-world
fuel savings may also drive the need for redundant power-net capability
THANK YOU